OPERATORSMANUAL

A DIVISION OF WELD TOOLING CORPORATION

3001 WEST CARSON STREET PITTSBURGH, PENNSYLVANIA USA 15204-1899 PHONE: 1- 800-245-3186 http://www.bugo.com TELEFAX: 1- 412-331- 0383

BWS-2000PORTABLE BOREWELDING SYSTEM

Please record your equipment identification information below for future reference. This information can be foundon your machine nameplate.

Model Number

Serial Number

Date of Purchase

Whenever you request replacement parts or information on this equipment, always supply the information youhave recorded above.

LIT-BWS-IPM-O404

TABLE OF CONTENTS

TITLE OF SECTION PAGE

1. SAFETY INFORMATION --------------------------------------------------------- 11.1. Machine Safety --------------------------------------------------------- 11.2. Operator Safety --------------------------------------------------------- 11.3. General Safety Requirements-------------------------------------- 11.4. Additional Safety Information-------------------------------------- 2

2. MAJOR COMPONENTS AND THEIR FUNCTIONS ---------------------- 22.1. Conduit Assembly ----------------------------------------------------- 22.2. Torch ----------------------------------------------------------------------- 22.3. Torch Mover-------------------------------------------------------------- 22.4. Other Support Components ---------------------------------------- 32.5. Tools Provided ---------------------------------------------------------- 3

3. SPECIFICATIONS ----------------------------------------------------------------- 3

4. ALIGNMENT ------------------------------------------------------------------------ 44.1. Parallelism --------------------------------------------------------------- 44.2. Concentricity ------------------------------------------------------------ 54.3. Axial Positioning ------------------------------------------------------- 6

5. WELDING TORCH - USE, COMPONENTS, AND RANGE ------------- 65.1. Liner Stick-Out ---------------------------------------------------------- 65.2 Liner Stick-Out Adjustment ----------------------------------------- 65.3. Mini Components ------------------------------------------------------ 65.4. Stub Components------------------------------------------------------ 65.5. Standard Components ----------------------------------------------- 75.6. Large Diameter Components -------------------------------------- 75.7. Outside Diameter Components ----------------------------------- 75.8. Attachment --------------------------------------------------------------- 75.9. Radial Adjustment ----------------------------------------------------- 75.10. Axial Adjustment ------------------------------------------------------- 8

6. CONDUIT ASSEMBLY INSTALLATION ------------------------------------- 8

7. FINAL PREPARATION FOR WELDING ------------------------------------- 8

8. WELDING ---------------------------------------------------------------------------- 9

9. SPECIAL SITUATIONS ---------------------------------------------------------- 99.1. Welding in High Temperature Environments ----------------- 99.2. Single Plane Welding ------------------------------------------------- 9

10. MAINTENANCE -------------------------------------------------------------------- 910.1. Spindle -------------------------------------------------------------------- 9

10.2. Extension Tube --------------------------------------------------------- 910.3. Remaining Components --------------------------------------------- 10

11. CARE---------------------------------------------------------------------------------- 10

ILLUSTRATIONS:Torch Mover and Support Components ----------------------------------- Fig 1Use of Standard Torch ---------------------------------------------------------- Fig 2Use of Large Diameter and OD Torch -------------------------------------- Fig 3Set-Up Information --------------------------------------------------------------- Fig 4In-Line Bore Setups -------------------------------------------------------------- Fig 5Cones - Using For Alignment ------------------------------------------------- Fig 6Wire Stability ----------------------------------------------------------------------- Fig 7Use of the “T” Base -------------------------------------------------------------- Fig 8“T” Base Support Configurations ------------------------------------------- Fig 9

APPENDIX:Useful Information:

1. Welding Time - Single Revolution --------------------------------- A2. Buildup Times ------------------------------------------------------------ A3. Deposition Rates -------------------------------------------------------- A

1. SAFETY INFORMATION. Many accidents are caused by operation and maintenance, which disregardbasic safety rules. Carefully read and adhere to the safety measures and precautions described in thisinstruction manual.

1.1. Machine Safety.1.1.1. The BWS-2000, while designed to be durable, is not designed to be dropped. Should you

do so, carefully inspect for damage. If any is found, repair or replace before continuingoperation.

1.1.2. Never leave the machine running unattended. Overtravel can result in machine damageand workpiece damage.

1.1.3. Keep the machine clean. Failure to do so can result in premature wear.1.1.4. Never remodel the machine.1.1.5. Never use the machine outdoors when the weather is wet. This could cause failure of the

machine and could cause a fatal accident by electric shock.1.1.6. The input electrical power rating for operating the BWS-2000 is 115 volts and 50 or 60 Hz.

Input power voltage which varies more than 10% from the above rating will damage theunit. Note:This refers to the electrical power to run the rotation function, not thewelding power or electrical power required to run the welding power supply.

1.1.7. The BWS-2000 should only be powered from properly grounded three prong outlets. Allelectrical connections should only be made in accordance with the appropriate andapplicable national and local electrical codes by a qualified electrician. Note: When usingthe BWS-2000 in a location where the power requirements listed in 1.1.6. above arenot available, a 150 (minimum) volt-ampere isolation transformer should be used toprovide said requirements.

1.2. Operator Safety.1.2.1. Read this instruction manual before setting-up or operating the BWS-2000.1.2.2. Always use a protective eye shield which conforms to ANSI Z87.1 standards when

observing the machine in use. Observing the arc directly or its reflection, without the useof such a shield can result in permanent eye damage.

1.2.3. Always use approved safety glasses with side shields when setting up or running theBWS-2000.

1.2.4. Anyone being exposed to the arc or its reflection should wear protective clothing over asmuch exposed skin as possible. Other areas should use a “sun block” cream with anappropriate “SPF” value.

1.2.5. Anyone close to the welding operation should wear heavy flame resistant clothing forprotection from sparks and flame.

1.2.6. The operator should not use loose clothing which might get wrapped around the rotatingmembers of the BWS-2000.

1.2.7. Before connecting the power plug make sure that the enable switch is in the OFF position.1.2.8. Removal of the machine cover without disconnecting the power may result in dangerous

electrical shock.1.2.9. Gases and fumes may be produced by the welding process which are dangerous to

breathe and should be avoided. Only use the BWS-2000 where there is adequateventilation.

1.2.10. Do not contact electrically live parts. Dangerous electrical shock may result.1.2.11. Do not operate the machine in damp areas or on metal floors without adequately insulating

yourself from the ground, the machine or machine components, or the workpiece.1.2.12. Make sure the BWS-2000 is adequately secured before using - especially when using in

an elevated location. Falling and striking the operator or others could cause serious injury.1.2.13. Always wear a “hard hat” when using the BWS-2000 in an elevated location or when near

others working in an elevated location.

1.3. General Safety Requirements.1.3.1. Keep the welding area neat and free from combustible materials - especially near

locations where welding spatter might land.1.3.2. A fire extinguisher should be readily available when welding.1.3.3. Inspect all electrical cables and conduits for signs of wear and replace or repair as

1.

required before use of the equipment.1.4. Additional Safety Information. (1) Recommended reading for users in the USA: “Safety in

Welding and Cutting”, American National Standard ANSI Z49.1, which can be purchased from theAmerican Welding Society, Inc., 550 NW Lejeune Road, Miami, FL 33126, USA. TelephoneNumber is 1-800-443-9353. (2) Users outside the USA refer to the relevant safety regulationspromulgated by the appropriate competent authority for your location.

2. MAJOR COMPONENTS AND THEIR FUNCTIONS.

2.1. Conduit Assembly. Provides a connection between the power supply and torch, and allows thetransmission of welding current, shielding gas, and welding wire. See Figure #1.2.1.1. Connector. Connects the Conduit to the wirefeeder. Type: EuroConnector, also known

as the Binzel KZ-2.2.1.2. Conduit. Flexible connection between the wirefeeder and the BWS-2000.2.1.3. Extension Tube. Allows the Torch to be extended to reach the bore to be welded.2.1.4. Liners. Liners extend from the wirefeeder to the welding Tip.2.1.5. Torch Swivel. Allows the Torch to be pivoted to reach the diameter to be welded.2.1.6. Swivel Lock. Locks the Torch in the desired angular position.2.1.7. Welding Switch. Allows the welding process to be turned ON and OFF.2.1.8. Welding Switch Cord. Allows the welding switch to be remotely operated.

2.2. Torch. Specially designed welding torch for the building up of bores. See Figure #2.2.2.1. Torch Body. Attaches to the Torch Swivel, and provides an attachment location for the

Diffuser and support of the liner. The body also conveys electric current, and shieldinggas for welding.

2.2.2. Standard Torch Extender. Can be inserted between the Torch Swivel and the Torch Bodyto allow greater diametric reach of the Torch.

2.2.3. Diffuser. Attaches to the Torch Body, and provides for attachment of the Tip and Nozzle,and support and positioning of the end of the liner. It also conveys electric current, andshielding gas.

2.2.4. Tip. Attaches to the Diffuser, and conveys wire for the welding process. It also transferselectric current to the wire.

2.2.5. Nozzle. Attaches to the Diffuser and directs shielding gas to the welding location.2.2.6. Torch Locking Nut. Locks the Torch in the desired angular position.

2.3. Torch Mover. Provides the necessary motion and speed adjustment to allow the build up ofbores of various sizes. See Figure #1.2.3.1. Housing. The backbone of the Torch Mover. Encloses necessary electrical and

mechanical components.2.3.2. Spindle. Supports the Extension Tube and provides the necessary motion for welding.2.3.3. Tube Clamp. Provides a rigid attachment to and telescoping of the Extension Tube, as

well as an upper stop for the Spindle.2.3.4. Spindle Collar. Provides a lower stop for the Spindle and Spindle support and position

when doing a single plane weld.2.3.5. Clutch Lever. Allows the Clutch to be disengaged for rapid positioning of the Spindle.

The Clutch Lever can also be locked for single plane welding.2.3.6. Rotation Direction Switch. Determines the direction of rotation of the Spindle. This

switch also has a center OFF position.2.3.7. Rotation Speed Knob. Determines the speed of rotation of the Spindle.2.3.8. Cooling Gas Fitting. Allows the introduction of cooling gas to allow the use of the BWS-

2000 in severe heat conditions.2.3.9. Support Bracket. Provides support to the Torch Mover at 8 positions around the

centerline.2.3.10. Power Cord. Provides electrical power to the BWS-2000 to drive the rotation motor.

Required input is 115v, 50/60 Hz.2.3.11. Receptacle. Provides a fused connection for the Power Cord.

2.

2.4. Other Support Components. Provide a connection between the Support Bracket andattachment to a rigid surface. See Figure #1.2.4.1. Support Rod. Provides support and axial adjustment for the BWS-2000.2.4.2. Swivel Base. Supports and allows the Support Rod to be adjusted to be parallel to the

bore axis. Anchor the Swivel Base by tack welding or clamping. Use the Swivel Basewhen aligning the BWS-2000 with Centering Cones.

2.4.3. Tack Nut. Supports the Support Rod. Does not allow adjustment of the Support Rodonce tack welded in place. Typically used when the attachment surface is known to beperpendicular to the axis of the bore, and when other means of support are not availableor are not practical.

2.4.4. “T” Base. Supports the Support Rod and provides a simple means for manual parallelismand concentricity adjustment.

2.4.5. Base Extender. Is bolted to the “T” Base and extends the point of attachment of theSupport Rod 3 inches toward the center of the bore, thereby allowing the welding of largerbores.

2.4.6. Radial Support. Attaches at one end to the Support Bracket and at the other end to theSupport Rod. It projects the BWS-2000 4 inches from the Support Rod and allows thewelding of larger diameter bores. It also allows the BWS-2000 to be moved closer andfarther from the point of attachment as required, thereby providing centering capabilities.An 8 inch Radial Support is also available.

2.4.7. Tack Plate. Supports, and provides an attachment location and alignment for the “T”Base. To be welded to a rigid support at an appropriate location to allow the BWS-2000 tobe centered over the bore to be built up.

2.4.8. Rod Collar. Provides support for the BWS-2000 when the Support Bracket or RadialSupport clamps are loosened. This is especially useful when setting up to weld a verticalaxis bore.

2.5. Tools Provided.2.5.1. Hex Wrench, 3/4”. Use on the “T” Base Leveling Bolts and Clamping Nut.2.5.2. Hex Wrench, 9/16”. Use on the Support Ball clamp, and Machine and Radial Support

clamp hex head cap screws.2.5.3. Allen Wrench, 1/2”. Use on the Base Extender bolts.2.5.4. Allen Wrench, 1/4”. Use on Support Plate socket head cap screws.2.5.5. Allen Wrench, 3/16”. Use on Tube Clamp, Spindle Collar and Support Rod Clamp socket

head cap screws, and Center Cones socket set screws.2.5.6. Allen Wrench, 5/64”. Use on Liner end socket set screws.2.5.7. Support Rod Tightener. Use to tighten Support Rod.

3. SPECIFICATIONS.3.1. Weight (Positioner and Torch). 11.4 kg (25 lb.)3.2. Diameter Range.

3.2.1. Standard ID Torch. 32 to 204 mm (1.25 to 8 in.)3.2.2. Standard ID Torch w/Extender. 32 to 280 mm (1.25 to 11 in.)3.2.3. Large ID Torch w/Extenders. 200 to 610 mm (8 to 24 in.)3.2.4. Standard OD Torch. 0 to 305 mm (0 to 12 in.)

3.3. Torch Reach (ID) – w/Extender. 1070 mm (42 in.)3.4. Torch Reach (OD; Minimum) – 204 mm (8 in.)3.5. Maximum Uninterrupted Axial Weld Length. 170 mm (6.7 in.)3.6. Maximum Continuous Welding Current - Standard. 140A3.7. Welding Process. MIG (GMAW)3.8. Welding Wire Diameter Range. .8 to 1.2 mm (.030 to .045 in.). Note: The recommended wire

diameter for welding steel is .8 mm (.030 in.).3.9. Operating Conditions. Complies with Standards EN60204-1/EN60974-1.3.10. Housing Cooling with Compressed Air. Recommended when working for sustained periods in

environments with temperatures greater than 200 degrees Fahrenheit. Attach air line to BWS-2000 using 1/8 NPT.

3.

4. ALIGNMENT OF THE BWS-2000 TO THE BORE BEING WELDED. Alignment is comprised of threemajor factors: (1) Parallelism - Positioning the axis of the BWS-2000 parallel with the axis of the borebeing welded, (2) Concentricity - Positioning the axis of the BWS-2000 directly in-line with the axis ofthe bore, and (3) Axial Positioning - Positioning the torch in a beginning axial location where it can weldas much of the bore as possible without stopping. See Figures #4, 5, 8 & 9.

4.1. Parallelism. The BWS-2000 is designed to allow parallelism alignment in several ways: (1)Unassisted, (2) Use of the Centering Cones, (3) Alignment directly from a boring bar, and (4)Attachment to an aligned boring bar adapter.

4.1.1. Unassisted.4.1.1.1. Weld the Tack Plate on a rigid support so that the Anchor Bolt is the appropriate

distance from the center of the bore to be welded, and the surface of the TackPlate is within 5° of being perpendicular to the axis of the bore. Notes: (1) SeeFigures #9 & 10 in order to determine the Anchor Bolt to bore-center distance,as well as appropriate support components for the size of bore to be welded. (2)The Support Bracket can be attached to the BWS-2000 in any one of 8 angularpositions around the Spindle centerline in order to facilitate the ease ofattachment and use of the BWS-2000. This feature is particularly important whenspace is limited.

4.1.1.2. Attach the “T” Base to the Tack Plate by setting the Base over the Anchor Bolt sothat the Anchor Bolt protrudes through the Base slot, installing a ½ inch FlatWasher, 4 Spring Washers, and locking it into place with a ½-13NC ClampingNut. See Figure #8.

4.1.1.3. Screw the Support Rod into the “T” Base.4.1.1.4. Adjust the Leveling Screws until the Support Rod is parallel to the bore axis. This

can most easily be accomplished by adjusting the 2 Screws at the top of the “T”,first to get one plane of adjustment aligned with the bore, and then the singleScrew at the bottom of the “T” to get the perpendicular plane of adjustmentaligned with the bore. See Figure #8.

4.1.1.5. Adequate parallelism in each of these planes of adjustment can be judged byinserting a straight edge into the bore, aligning it parallel to the bore axis, andsighting or measuring the distance between the Support Rod and straight edgefor each plane.

4.1.1.6. A level can also be used to achieve parallelism if the axis of the bore is known tobe either horizontal or vertical.

4.1.2. Centering Cones. The use of centering cones is a good choice when there are two ormore in-line bores to be welded. The use of centering cones as described below achievesnot only parallelism, but also concentricity. See Figure #6.4.1.2.1. Slide a 31.75 mm (1.25 in.) diameter tube or rod of sufficient length to reach into

at least two of the bores to be welded.4.1.2.2. Slide two Centering Cones onto the tube - one onto each end. Lock one of the

cones onto the tube and then slide the other cone into the bore until it forces thetube and opposite-end cone to the center of the bore. Once so centered, lock thesecond cone into position.

4.1.2.3. Slide the BWS-2000 - minus the Conduit Assembly - over the centering tube.(The tube will now extend through the Spindle.)

4.1.2.4. Weld or clamp the Swivel Base or Tack Nut while attached to the BWS-2000 to anappropriate rigid support.

4.1.2.5. After tightening all support clamping screws, the Centering Cones and tube canbe removed and the Conduit Assembly inserted in the Spindle for welding.

Note: An alternative but similar method involves the use of bushings instead ofcones. In this instance, bushings with OD’s nearly as large as the bores and ID’s1.25 inches in diameter, are inserted into the bores. A 1.25 inch diameter tube orrod is then inserted through the ID’s of the bushings. The tube/rod is nowcentered in the bore. Proceed as in 4.1.2 above.

4.

4.1.3. Alignment from Boring Bar. If the boring bar is to be set-up before welding the bore, thismethod is preferred over alternatives due to its speed and accuracy.4.1.3.1. If a 31.75 mm (1.25 in.) diameter boring bar is used, slip the BWS-2000, with the

Torch Assembly removed, on the boring bar at the axial location desired. If a largerdiameter boring bar is used, remove the boring bar, install bushings in the boring barbearing ID’s, insert a 31.75 mm (1.25 in.) diameter tube in the bushings, and slip theBWS-2000 on the tube.

4.1.3.2. Weld or clamp the Swivel Base or Tack Nut while attached to the BWS-2000, to anappropriate rigid support.

4.1.3.3. Remove the boring bar and insert the Conduit Assembly in the Spindle for welding.Note: It may be necessary to remove the boring bar, bearing insert or the entirebearing in order to allow the torch to have adequate radial reach.

4.1.4. Boring Bar Adapter. Several manufacturers of popular boring bars offer adapters whichallow attachment of the Support Rod and assure its alignment. Once so aligned, the SupportBracket can be directly attached to the rod and the BWS-2000’s axis will be reasonablyparallel to the bore to be welded.

4.2. Concentricity. Use of centering cones, as described above, provides concentricity of the BWS-2000as well as parallelism. However, unassisted set up or use of a boring bar adapter generally requiressome additional adjustment in order to achieve concentricity. This adjustment is done afterparallelism adjustments have been completed.4.2.1. Unassisted. Achieving concentricity when doing an unassisted set up will typically require the

adjustment of two axes. See Figure #8.4.2.1.1. By using the attached Support Bracket, set the BWS-2000 on the Support Rod at an

appropriate axial location. Note:If the axis of the bore to be welded is vertical ornearly vertical, the use of a 1 ¼ inch diameter locking Rod Collar located under theradial support is recommended. Use of this collar when locked into the appropriateposition on the Support Rod, allows the free rotation of the Radial Support without thenuisance of it sliding down the Support Rod.

4.2.1.2. If not already in place, insert the Conduit Assembly in the Spindle and clamp. Also,install the Torch.

4.2.1.3. Attach the Power Cord to the BWS-2000 and energize with 115v, 50 or 60 Hzelectrical power. The Spindle should now be capable of rotating when the RotationDirection Switch is in either of its active positions.

4.2.1.4. Extend the Torch into the bore to be welded either by disengaging the Clutch andmanually moving the Spindle, or by unclamping the Tube Clamp and extending theExtension Tube.

4.2.1.5. Once into the bore, rotate the Torch until the Nozzle is pointing toward, and thendirectly away from the Support Rod. Note the distance from the end of the Nozzle tothe bore wall for both of these positions. If these distances are not equal, loosen theAnchor Nut and slide the “T” Base until the distances are equal. Retighten theAnchor Nut. This completes the centering process for one axis.

4.2.1.6. Rotate the Torch 90 degrees from the positions just used in order to achieve the firstaxis of centering, ie., perpendicular to a line running between the bore center and theSupport Rod.

4.2.1.7. Note the distance of the Nozzle from the bore wall and again rotate the Torch 180degrees and compare the Nozzle/wall distance.

4.2.1.8. Adjust the Nozzle/wall distances by unclamping the Support Bracket from the SupportRod, and swiveling the BWS-2000 around the Support Rod until the Nozzle/walldistance is equal at both positions. Reclamp the Support Bracket to the SupportRod.

4.2.1.9. The Torch should now be centered in the bore and the centerlines of the bore and theBWS-2000 parallel. Rotate the Torch 360° at the top and bottom of the bore toconfirm. Note: Nozzle to wall distance consistency of from 1 to 1.2 mm (.04 to .05in.) is generally adequate.

4.2.2. Boring Bar Adapter Assisted. Use of a boring bar adapter generally provides the first axis ofcentering and does not require the use of the Radial Support. Follow the instructions abovefrom 4.2.1.6. thru 4.2.1.9. in order to achieve second axis centering.

5.

4.3. Axial Positioning. Several factors can affect the axial position of the various components, andtherefore the axial range of the welding process. They include the: (1) Location of attachment ofthe Tack Plate or Swivel Base, (2) Position of attachment on the Support Rod, (3) Axial positionof the Spindle, and (4) Axial position of the Extension Tube. See Figure #4.4.3.1. Location of Tack Plate or Swivel Base. For most welding situations there is only one

logical mounting surface - adjacent to one of the bores to be welded, and at about thesame plane as on end. When several in-line bores are to be welded, it might be desirableto attach the Tack Plate or Swivel Base between the bores, thereby allowing an easy reachto bores on either side. This is possible because the Extension Tube can be inserted inthe Spindle with the torch coming out of either end of the BWS-2000. The only changethat has to be made to accommodate reversing the position of the torch is swapping thelocations of the Spindle Collar and the Tube Clamp. See Figure #5.

4.3.2. Position of the BWS-2000 on the Support Rod. The Support Rod is 560 mm (22 in.) long.The Radial Support or Support Bracket can be positioned along the rod wherevernecessary.

4.3.3. Axial Position of the Spindle. The axial position of the Spindle determines the length ofstroke available for welding before repositioning is necessary. It should be consideredalong with other axial position contributors, and the length of the bore when determiningthe best combination. The axial position of the Spindle is changed by disengaging theClutch and manually sliding the Spindle to the desired location.

4.3.4. Axial Position of the Extension Tube. The position of the Extension Tube and Spindleallows bores located approximately 1000 mm (40 in.) away from the Tack Plate mountingsurface to be welded. This extension capability allows the quick movement of the torchfrom bore to bore. The position of the Extension Tube is changed by loosening the TubeClamp and manually extending or retracting the Extension Tube to the desired location.Note: In order to maintain stability of the Torch, the Extension Tube should not protrudebeyond the end of the Tube Clamp more than 530 mm (22 in.).

5. WELDING TORCHES. The BWS-2000 has the capability of welding inside diameters from 32 to 940mm (1.25 to 37 in.) and outside diameters up to 305mm (12 in.). Welding this range of diameters isachieved by using either the Standard, Large Diameter or OD Torch, using the appropriate nozzle, tip,diffuser and extender, and by pivoting the torch to the proper radial location. See Figures #2, 3 & 4.Note: (1) In order to keep weight and electrical resistance to a minimum, many of the Torchcomponents are manufactured out of aluminum. Take care not to overtighten these components asdamage to the threads may result. (2) The ID Torches are coated to prevent accidental arcing tothe torch bodies. Take care not to wear off the coating.

5.1. Liner Stick-Out. Proper Liner stick-out from the end of the Torch before installing a Diffuser is afollows: (1) Standard Diffuser – 29 mm (1.15 in.); (2) Mini Diffuser – 6 mm (.25 in.). See Figure#2.

5.2. Liner Stick-Out Adjustment. The Liner stick-out can be adjusted by loosening the TorchAttachment Locknut and screwing the Torch either in or out as necessary to provide proper stick-out. Following adjustment, the Torch Attachment Locknut should be retightened. See Figure #2.

5.3. Mini Components. Use the Standard Torch with these components in order to weld borediameters from 32 to 50 mm (1.25 to 2 in.). See Figure #2.5.3.1. Diffuser, Mini (PN. 1093). Screws into the Standard Torch Body and contains the end of

the liner. It also supports the tip and nozzle, and transfers electrical power to the tip.5.3.2. Tip, Stub (PN. 1058). Screws into the diffuser and provides transfer of electrical power

from the diffuser to the welding wire.5.3.3. Nozzle, Mini (PN. 1092). Screws onto the diffuser and directs the shielding gas.

5.4. Stub Components. These components, when used with the Standard Torch, allow the welding ofdiameters as small as 45 mm (1.8 in.). They are capable of being used to weld diameters aslarge as 145 mm (5.7 in.). See Figure #2.5.4.1. Diffuser (PN. 1057). Screws into the torch body and contains the end of the liner. It also

6.

supports the tip and nozzle. Note: Attach only Diffuser numbers 1057 or 1093 to theStandard Torch. Use of other diffusers may cause damage to the liner and torchthreads.

5.4.2. Tip, Stub (PN. 1058). Screws into the diffuser and provides transfer of electrical powerfrom the diffuser to the welding wire.

5.4.3. Nozzle, Stub (PN. 1066). Screws onto the diffuser and directs the shielding gas. Thisnozzle is electrically isolated.

5.5. Standard Components. When used with the Standard Torch, these components allow thewelding of diameters from 70 mm to 204 mm (2.75 to 8 in.). See Figure #2.5.5.1. Diffuser (PN. 1057). Same use as above.5.5.2. Tip, Standard (PN. 1061). Same use as above.5.5.3. Nozzle, Standard (PN. 1067). Same use as above. Note: Only use Nozzles number

1066 and 1067 when attaching directly to the Standard Torch. Other Nozzles may losetheir electrical isolation when used with this torch.

5.5.4. Standard Torch Extender. Use of the Standard Torch Extender extends the length of theStandard Torch by 100 mm (4 in.). Its use increases the diameter capability of the abovecomponents by approximately 75 mm (3 in.). It is attached at the swivel end of theStandard Torch, and requires use of a liner segment about 4 inches longer than is usedwithout it. See Figure #2.

5.6. Large Diameter Components. The use of the Large Diameter Torch allows the welding of boresfrom 200 to 380 mm (8 to 15 in.). Use the same Diffuser, Tip, and Nozzle as are listed underStandard Components. If Torch Extenders are also used, the maximum diameter capability isextended to a maximum of 610 mm (24 in.). See Figure #3.5.6.1. Liner With Attached Tubular Liner Aligner. The Liner protruding from the Torch is

extended by slipping the Liner Aligner over the Torch Liner.5.6.2. Torch Extenders. Thread the lengthened liner through the Torch Extender(s) and screw

the Extender(s) on the Large Diameter Torch. The Liner should now protrudeapproximately 29 mm (1.15 in.) beyond the end of the Extender - cut as necessary.Installation of the Diffuser should now place the Liner in its proper orientation relative tothe Tip. Any of the Tips, Diffusers, or Nozzles listed above can be used with the LargeDiameter Torch. Note: When using the Large Diameter Torch,, Tweco Diffuser number35-50, and Nozzle number 21-62 are acceptable.

5.7. Outside Diameter Components. The use of the OD Torch, allows the build-up of outsidediameters from 0 to 305 mm (0 to 12 in.) for a minimum length of 204 mm (8 in.). Special torchbodies can be provided to accommodate diameter and length requirements outside of the rangeslisted above. All Tips, Diffusers, and Nozzles that are used with the ID Torches, can be used withthe OD Torch. See Figure #3.

5.8. Attachment of the Welding Torch. See Figure #2 & 3.5.8.1. Remove the Nozzle and Diffuser from the torch. This allows the Liner to be manually

deflected into the threaded diffuser-attachment-hole when it reaches that point duringtorch attachment.

5.8.2. Insert the end of the Liner coming out of the Conduit Assembly into the end of the Torch,and screw the Torch on the Torch Adapter.

5.8.3. Once adequate engagement is achieved, the liner is protruding through the diffuser-attachment-hole approximately 29 mm (1.15 in.) for the standard Diffuser and 6 mm (.25in.) for the Mini Diffuser, and the diffuser-attachment-hole is pointing in the direction ofTorch adjustment, screw the Torch Lock Nut until it tightens against the Torch, therebylocking the Torch into position.

5.9. Radial Adjustment of the Welding Torch. See Figure #2, 3 & 4.5.9.1. If tightly locked, loosen the Radial Adjustment Lock Nut.5.9.2. Pivot the Torch until the closest point of the Nozzle is about 2 to 4 mm (.08 to .16 in.) from

the inside of the bore (or outside of pin).5.9.3. Lock the Torch in position by hand tightening the Radial Adjustment Lock Nut.

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5.10. Axial Adjustment of the Welding Torch. (See 4.3. above.)

6. CONDUIT ASSEMBLY INSTALLATION. The Conduit Assembly extends all the way from the WirefeedConnector to the Torch Adapter. See Figure #7.6.1. Insert the Conduit Assembly into the Spindle, the Extension Tube end first. Note: (1) If the Torch

is attached, remove the Nozzle and Diffuser first. (2) Make sure that the Extension Tube is clean,by wiping it with a clean soft cloth to remove any loose dirt or buildup before installation. Failureto keep the Extension Tube clean could result in binding with the Spindle bore.

6.2. Clamp the Extension Tube in position using the Tube Clamp. It can be clamped with the torch-attachment-end from 0 to 560 mm (0 to 22 in.) from the end of the Tube Clamp.

6.3. Attach the flexible end of the Conduit Assembly to the wirefeeder.6.4. If possible, position the wirefeeder so that the Flexible Conduit is oriented in a “Stable Wire

Feeding Setup” similar to those shown in Figure #7. Weld beads produced by a stable wirefeeding setup will be straighter. Also, there will be much less likelihood of incomplete weldcoverage of the bore.

7. FINAL PREPARATION FOR WELDING.

7.1. Adjust the radial position of the Torch as specified above.7.2. Adjust the axial position of the Torch - using techniques specified above - to the desired starting

position so that the welding can proceed from the end of the bore farthest from the BWS-2000toward the BWS-2000. Generally an initial wire contact position of about 2 to 3 mm (.08 to .12 in.)from the start end of the bore is about right. Note: It is advisable - especially in vertical weldingapplications - to attach the conduit to the Radial Support, Support Rod or other stationary objectso that the conduit forms a large radius when exiting the Extension Tube or Spindle. This causesless friction for the welding wire traveling through the Conduit and less friction between theConduit and Extension Tube or Spindle. See Figure #4.

7.3. Set the Rotation Speed Knob to the proper setting based on the diameter to be welded. Anapproximate setting can be read from the chart on the side of the BWS-2000. This chart is basedon welding speeds of 500 mm (20 in.) per minute. Note: Rotation speeds will vary due todifferences in supply voltage and electrical components. To check the actual welding speeddivide circumference of the bore by the time in minutes required to traverse one full revolution.See Appendix A, paragraph #1.

7.4. Check to make sure that the Welding Switch at the end of the welding cord is in the Off position.Note: If the Welding Switch is not in the Off position dangerous welding flash may resultwhen the power supply is energized.

7.5. Energize the welding power supply.7.6. With the ground (-) and/or positive (+) welding leads disconnected, jog the welding wire through

the Conduit Assembly and Torch by depressing the “Jog Button” on your wirefeeder, or if yourwirefeeder does not have a “Jog Button”, move the Weld Switch to the “On” position. Once thewelding wire is through the Conduit Assembly and Torch, move the Weld Switch to the “Off”position. Cut the wire to an appropriate stick-out length. Notes: (1) If the welding leads arenot disconnected, a dangerous welding flash may result when the welding wire exits thetorch. (2) The Diffuser may have to be removed in order for the wire to get around the Liner bendjust before the Diffuser attachment point. Once the wire is through the Liner, the Diffuser (andTip) can be reinstalled.

7.7. Connect the welding current ground (-) lead to the part being welded. Note: Make sure that theground is connected to clean solid metal. A poor ground will adversely affect weld quality.

7.8. Make sure the power supply is set for Constant Voltage operation.7.9. Make sure that the bore to be welded is clean, ie., free from rust, dirt, oil, grease, etc. A dirty bore

will cause poor weld quality, and excessive spatter.7.10. Connect shielding gas. For mild steel welding, use an argon/CO2 mixture with an argon content

of from 75 to 92 percent. Set the flow rate to about 1 m3/hour (35 cfh or 16 litres/minute).7.11. Purge air from the system by depressing the purge button - typically located on the wirefeeder -

for approximately 10 seconds. This should be the last step before welding to assure that no airhas infiltrated the gas feed system.

8.

8. WELDING.

8.1. Make sure that all of the safety precautions mentioned in the Safety Information section of thismanual are being complied with before beginning welding.

8.2. Move the Rotation Direction Switch in the axial direction that the torch is supposed to travel. Thiswill start the rotary and axial motion.

8.3. At the same time that the Rotation Direction Switch is activated, the Weld Switch can beactivated. Note: At this time, the Clutch can be locked in the “disengaged” position for one Torchrevolution to allow a single plane of weld to be deposited before axial motion begins. Thisgenerally gives more complete buildup at the start of the weld.

8.4. Normal weld settings for mild steel are: Voltage - 16 to 17.5; Amperage - 100 to 135, althoughsuccessful welding can be done outside of these settings.

8.5. Adjust the rotation speed, voltage and wire speed settings as necessary to achieve the desiredresults. Be especially careful that the arc is “playing” at the intersection of the previous bead andthe base metal. If the arc is “playing” on the previous bead or in the molten weld puddle, poorfusion to the base metal may result.

8.6. When approaching an area where weld should not be deposited - such as a keyway - move theWeld Switch toggle to the “Off” position to stop welding. Rotation will continue. Once the far sideof the area is reached, move the Weld Switch to the “On” position to continue welding.

8.7. The BWS-2000 is designed to be “manned” when in use in order to make adjustments whennecessary, and to be available when the build up of the bore is completed or the end of the strokeis reached. Note: The BWS-2000 does not automatically shut off when the end of its stroke hasbeen reached. The Clutch will disengage briefly each revolution as the Spindle attempts to moveaxially. While no damage is likely for considerable time, such disengagement does causeexcessive wear, and if occurring during welding will leave a substantial deposit of weld at onelocation.

8.8. Once the build up is completed, shut off the Welding and the Rotation Switches.8.9. To continue welding the same bore or another in-line bore, reposition as indicated above, purge

the system, and begin as described earlier in this section.

9. SPECIAL SITUATIONS.

9.1. Welding in High Temperature Environments. It is suggested that when welding for extendedperiods in environments with temperatures of 93° Celsius (200° Fahrenheit) or greater, that theBWS-2000 housing be cooled by supplying compressed air to the housing interior through theCooling Fitting. The air supplied should be dry, and regulated down to a pressure of about 35Kilonewton per square meter (5 psi). The Cooling Fitting can be attached to by removing theCooling Fitting Plug, and screwing in a 1/8 NPT male fitting. When the air cooling is not in use,the Cooling Fitting Plug should be reinstalled to keep foreign matter out of the BWS-2000housing.

9.2. Single Plane Welding. The BWS-2000 clutch can be locked in the disengaged position bymoving the clutch lever to the detent location. If disengaged, the spindle will not move axiallywhen rotated, thereby allowing face or fillet welding. It also allows a single plane of weld to bedeposited on a cylindrical surface before axial motion begins. Moving the clutch lever out of thedetent position while welding is taking place will allow axial motion to take place during the nextrevolution. Note: When single plane welding, it is generally desirable to move the Spindle Collarto make contact with the Top Bushing, thereby maintaining the desired Spindle position.

10. MAINTENANCE. Very little maintenance is required except regular cleaning.

10.1. Spindle. The Spindle should be wiped down with a clean soft cloth after each use or morefrequently if in an excessively dirty environment. It can be moved from stop to stop so that mostof its length - including the threads - can be cleaned. No lubrication is necessary.

10.2. Extension Tube. There is minimal clearance between the Spindle ID and the Extension TubeOD. If the Extension Tube is not kept clean by regular wiping with a clean soft cloth, binding

9.

between the two can occur. Should movement of the Extension Tube become inhibited, remove itentirely from the Spindle and clean thoroughly. Also clean the ID of the Spindle at the same time.It is suggested that this procedure be done on a daily basis during periods of normal use.

10.3. Remaining Components. All remaining components should be wiped clean on a daily basis.These include the housing, mounting components, torches, cords, and conduits.

11. CARE. The BWS-2000 is designed to be used in an industrial environment, but like any tool requiresreasonable care in order to function as intended.

11.1. The BWS-2000 is designed to be corrosion resistant in order to function properly in humidenvironments. It is not however, designed to be used in the rain or to be immersed in water.Should the unit accidentally get wet, thoroughly dry before using. Using the BWS-2000 wetcould damage the unit as well as create a hazardous situation.

11.2. The BWS-2000 should not be dropped or struck with any object. Should this happen, thoroughlyexamine it - especially the Spindle threads and surface - for damage. Repair or replace anydamaged components before use.

11.3. Inspect all electrical cords for damage. Repair or replace them before use.11.4. Be careful not to expose the BWS-2000 to excessive heat or damage will occur.

10.

Torch Mover And Support ComponentsFigure #1

11.

CONDUIT(2.1.2.)

EXTENSIONTUBE (2.1.3.)

SPINDLE (2.3.2.)

SPINDLECOLLAR(2.3.4.)

TORCHMOVER(2.3.)

TUBECLAMP(2.3.3.)

TORCHSWIVEL

(2.1.5.)

SWIVELLOCK

(2.1.6.)

TORCH(2.2)

SUPPORT ROD(2.4.1.)

RODCOLLAR(2.4.8.)

SUPPORTBRACKET(2.3.9.)

ROTATIONDIRECTION

SWITCH(2.3.6.)

CLUTCHLEVER(2.3.5.)

CLUTCHLEVER

DETENT

ROTATIONSPEED KNOB

(2.3.7.)

HOUSING(2.3.1.)

COOLING GASFITTING (2.3.8.)

RECEPTACLE(2.3.11)

WELDINGSWITCH

(2.1.7.)

“T” BASE(2.4.4.)

SUPPORT RODTIGHTENER(2.5.7.)

Use

Of S

tand

ard

Torc

h

Diff

user

BW

S-10

93

Adj

ust l

iner

stic

kout

to 6

.3m

m (.

25")

Dia

met

er R

ange

-32

to 5

0 m

m(1

.25

to 2

inch

es)

Dia

met

er R

ange

-45

to 1

45 m

m(1

.8 to

5.7

inch

es)

Dia

met

er R

ange

-79

to 2

03 m

m(2

.75

to 8

inch

es)

Dia

met

er R

ange

-70

to 2

70 m

m(2

.75

to 1

1 in

ches

)

Noz

zle

BW

S-10

66

Tip

BW

S-10

58

Diff

user

BW

S-10

57

Noz

zle

BW

S-10

67

Tip

BW

S-10

61

Diff

user

BW

S-10

57

Swiv

el L

ock

(2.1

.6)

Torc

h Lo

ck(2

.2.6

)

Adj

ust t

orch

axia

lly to

ach

ieve

prop

er li

ner

stic

kout

.

Adj

ust a

s ne

eded

.

Line

r B

WS-

1039

(2.1

.4) (

TYP)

Set s

ticko

ut to

29

mm

(1.1

5") a

nd a

lign

torc

hso

line

r is

poin

ting

in th

edi

rect

ion

of p

ivot

.

Noz

zle

(2.2

.5)

Tip

(2.2

.4)

Diff

user

(2.2

.3)

Stan

dard

Com

pone

nts

With

Tor

ch E

xten

der.

Stan

dard

Com

pone

nts.

Stub

Com

pone

nts.

Min

i Com

pone

nts.

Figu

re #

2

12.

Torc

hB

ody

BW

S-11

04(2

.2.1

) (T

YP)

Torc

hEx

tend

erB

WS-

1105

(2.2

.2)

Tip

BW

S-10

58

Noz

zle

BW

S-10

92

Use

Of L

arge

Dia

met

er a

nd O

D T

orch

Figu

re #

3

Dia

met

er R

ange

-12

.7 to

305

mm

(.5 to

12

inch

es)

Torc

h B

ody

BW

S-A

114

Torc

h Ex

tens

ion

Tube

BW

S-10

42

Line

r Alig

ner

BW

S-10

43

Noz

zle

BW

S-10

67

Diff

user

BW

S-10

57 (T

YP)

Tip

BW

S-10

61

29 m

m(1

.15"

)

Torc

h B

ody

BW

S-A

115

Line

r B

WS-

1039

(alig

n to

rch

soth

at li

ner i

spo

intin

g in

the

dire

ctio

n of

piv

ot)Adj

ust t

orch

axi

ally

toac

hiev

e pr

oper

line

r st

icko

ut

Adj

ust a

s ne

eded

Torc

h at

tach

men

t loc

knut

Rad

ial a

djus

tmen

t loc

knut

Torc

h A

ttach

men

t and

Rad

ial A

djus

tmen

tSt

anda

rd C

ompo

nent

sEx

tend

ed R

ange

Com

pone

nts

Out

side

Dia

met

erTo

rch

Dia

met

er R

ange

-1

exte

nsio

n: 3

80 to

610

mm

(15

to 2

4")

Dia

met

er R

ange

-20

0 m

m to

380

mm

(8 to

15"

)

13.

Gen

eral

Set

up In

form

atio

n

Figu

re #

4

Opt

iona

lco

ndui

tsu

ppor

ttu

be

Alte

rnat

ive

met

hod

ofco

ndui

t sup

port

Rub

ber

stra

p-su

ppor

ts c

ondu

it to

achi

eve

grad

ual

swee

p of

con

duit

atto

p of

BW

S-20

00

Con

duit

(to w

irefe

eder

)

Swiv

el b

ase

(wel

d or

cla

mp

in p

lace

)

WO

RK

PIEC

E TO

BE

WEL

DED

Opt

iona

lco

ndui

tsu

ppor

ttu

be

Rad

ial

supp

ort

Supp

ort

Cla

mp

Supp

ort R

od(a

lign

para

llet

ot b

ore

cent

erlin

e)

Torc

h pi

vot

mec

hani

sm

Exte

nsio

n tu

be

Exte

nsio

ntu

becl

amp

Min

imun

dist

ance

toal

low

bui

ldup

of b

ore

340

mm

(13.

5")

BW

S-20

00

14.

In-L

ine

Bor

e Se

t-Ups

Figu

re #

5

Side

Atta

chm

ent

Cen

tral

Atta

chm

ent

(Nor

mal

Tor

ch O

rient

atio

n)

Cen

tral

Atta

chm

ent

(Inve

rted

Tor

ch O

rient

atio

n)

15.

Usi

ng C

ones

For

Alig

nmen

t

Figu

re #

6

Lock

scr

ew(T

YP)

Cen

terin

g ro

d31

,75

mm

dia

.(1

.25"

)

Cen

terin

g co

ne(T

YP)

T TYP

(3)

Tack

pla

te

TT

NO

TE: W

eld

or c

lam

p Ta

ck P

late

in p

lace

and

tigh

ten

all s

crew

s or

nut

s la

bele

d “T

” be

fore

rem

ovin

g C

ente

ring

Rod

.

16.

Wire

Sta

bilit

y

Figu

re #

7

Wire

cas

t and

con

duit

curv

atur

e ar

e in

the

sam

e di

rect

ions

Wire

cas

t and

con

duit

curv

atur

e ar

e in

the

sam

e di

rect

ions

Wire

cas

t and

con

duit

curv

atur

e ar

e in

opp

osite

dire

ctio

ns

Wire

cas

t and

con

duit

curv

atur

e ar

e in

opp

osite

dire

ctio

ns

Wire

cas

t and

con

duit

curv

atur

e ar

e in

opp

osite

dire

ctio

nsUns

tabl

e W

ire F

eedi

ng S

etup

s

Stab

le W

ire F

eedi

ng S

etup

s

NO

TE: W

eldi

ng w

ire in

not

str

aigh

t. Th

e di

rect

ion

itcu

rves

is c

alle

d th

e w

ire c

ast.

“A”

repr

esen

ts w

ireca

st.

17.

Use

of t

he B

SW “

T” B

ase

Figu

re #

8

Mou

nt D

etai

l

(4) S

prin

gw

ashe

rs

Tack

Pla

te

Anc

hor n

ut(1

/2-1

3 N

C) “T

” B

ase

Wor

kpie

ce

Tack

pla

teta

ck w

eld

orcl

amp

tow

orkp

iece

ACB D

180

mm

(7") Su

ppor

t rod

“T”

Bas

eR

odm

ount

Posi

tions

Para

llelis

m A

djus

tmen

t(O

bjec

tive

- alig

n su

ppor

t rod

par

alle

l to

bore

cen

terli

ng)

1. T

o ad

just

in d

irect

ions

A -

B m

ove

scre

ws

1 &

2.

2. T

o ad

just

in d

irect

ions

C -

D m

ove

scre

w 3

.3.

Loo

sen

and

retig

hten

anc

hor n

ut a

s ne

cess

ary

to p

erfo

rmab

ove

adju

stm

ents

.

Con

cent

ricity

Adj

ustm

ent

(Obj

ectiv

e - c

ente

r BW

S-2

000

with

wor

kpie

ce b

ore)

1. L

oose

n an

chor

nut

.2.

Slid

e “T

” bas

e to

cen

ter t

orch

in th

e E

- F

dire

ctio

n.3.

Tig

hten

anc

hor n

ut.

4. L

oose

n su

ppor

t rod

cla

mpi

ng n

ut.

5. R

otat

e B

WS

-200

0 ar

ound

sup

port

rod

to c

ente

r tor

ch in

the

G -

H d

irect

ion.

6. R

etig

hten

sup

port

rod

and

clam

ping

nut

.

19.

“T”

Bas

e Su

ppor

t Con

figur

atio

ns

Figu

re #

9

Supp

ort r

od

“T”

base

152

mm

(6")

Anchor Bolt Location

356

mm

(14"

)

Supp

ort r

od lo

catio

n #2

Bas

eex

tend

er

“T”

base

Supp

ort

rod

Rad

ial

Supp

ort

Anchor Bolt Location

Bas

e Ex

tend

er &

Rad

ial S

uppo

rt A

dded

Supp

ort r

od

Bas

e Ex

tend

er A

dded

“T”

base

Anchor Bolt Location

Bas

eex

tend

er254

mm

(10"

)

“T”

base

Supp

ort r

od

Anchor Bolt Location

180

mm

(7")

Max

bor

e O

114

mm

(4.5

") Max

bor

e O

520

mm

(20.

5")

Max

bor

e O

165

mm

(6.5

")

Max

bor

e O

318

mm

(12.

5")

20.

USEFUL INFORMATIONAPPENDIX A

1. NORMAL TIME OF ONE REVOLUTION OF THE TORCH WHILE WELDING.(Useful when setting up the BWS-2000)

Metric - Calculate by multiplying the diameter (mm) by .38.Example: Diameter or bore = 180 mm.

Normal revolution time = 180 x .38 = 68 seconds

English - Calculate by multiplying the diameter (in.) by 10.Example - Diameter of bore = 3.5 inches.

Normal revolution time = 3.5 x 10 = 35 seconds.

2. NORMAL TIME TO BUILD UP A BORE(Useful when estimating job times.)

Metric - Calculate by multiplying the diameter (mm) by the length (mm) by .002.Example: Diameter of bore = 65 mm; Length of bore = 110 mm.

Normal build up time = 65 x 110 x .002 = 14.3 minutes.

English - Calculate by multiplying the diameter (in.) by the length (in.) by 1.25.Example: Diameter of bore = 4.2 inches; Length of bore = 3.6 inches.

Normal build up time = 4.2 x 3.6 x 1.25 = 18.9 minutes

3. WIRE DEPOSITION RATE.(Useful when calculating anticipated wire usage.)

Metric - Calculate by multiplying the following:For .8 mm wire - Multiply the wirefeed speed in mm/min. by .00022.For .9 mm wire - Multiply the wirefeed speed in mm/min. by .00030.

Example: Wirefeed rate = 7400 mm/min.; Wire diameter = .8 mm.Deposition rate = 7400 x .00022 = 1.63 kg/hr.

English - Calculate by multiplying the following;For .030 in. wire - Multiply the wirefeed speed in in./min by .0123.For .035 in. wire - Multiply the wirefeed speed in in./min. by .0167For .045 in. wire - Multiply the wirefeed speed in in./min. by .0277

Example: Wirefeed rate = 320 in./min.; Wire diameter = .030 in.Deposition rate = 320 x .0123 = 3.94 lb./hr.

21.

BWS-2000 PORTABLE BORE WELDING SYSTEMCOMPONENT LISTWeldingTipsStub Tips:BWS-1058 .8mm (.030)BWS-1059 .9mm (.035)BWS-1060 1.2mm (.045)

Standard Tips:BWS-1061 .8mm (.030)BWS-1062 .9mm (.035)BWS-1063 1.2mm (.045)

Welding Nozzles and DiffusersMini Nozzle:BWS-1092 32-50mm (1.25-2")

Stub Nozzle:BWS-1066 Use for small diameters

Standard Nozzle:BWS-1067 Use for large diameters

Mini Diffuser:BWS-1093 32-50mm (1.25-2")

Diffuser:BWS-1057 Use with all torches

Welding Torches and AccessoriesStandard Torch:BWS-A113 32-204mm (1.25-8")

Large Diameter Torch:BWS-A115 200-380mm (8-15")

Standard Torch Extender:BWS-A116 Increase dia 76mm (3")

Torch Extension Tube:BWS-1042 Diameter Ranges: 1 Tube - 380-580mm (15-23") 2 Tubes - 530-760mm (21-30")

OD Torch:BWS-A114 0-305mm (0-12")

Hand held MIG gun and conduit:BWS-1102 3.6m (12') conduit w/euro

Face Torch:BWS-A127 0-610mm (0-24")

Support ComponentsTack Nut:BWS-1100 Non-adjustable support

“T” Base:BWS-A110 Leveling & centering adjustments

Tack Plate:BWS-1099 Weld/clamp to part & support “T”

Swivel Base:BWS-A106 Use with centering cones & tube

Base Extender:BWS-1097 Attach to “T” for large bore reach

Radial Support Extender 102mm (4")BWS-A118 Extra reach for large bores

Radial Support Extender 203mm (8")BWS-A119 Extra reach for large bores

Centering ComponentsCentering Cone Set:BWS-A108 45-160mm (1.8-6.4")

Centering Tube:BWS-1044 1.8m (72")

MiscellaneousLiner:BWS-1039 1.5m (60") for torches

Liner, Conduit ReplacementBWS-1038 4.5m (15')

Thru-Bar bore measuring tool kit: (46-305mm)(1.8-12")BWS-A131 For use with boring bar

Liner Aligner:BWS-1073 Use with torch extension tubes

Welding wire, large diameter cast 70S6BWS-1103 30 lb. spool .8mm (.030")BWS-1202 30 lb. spool .9mm (.035")

Auto-Skip Option:BWS-A129 enables partial borewelds

Call factory for specials, boring bar systems and components or power supply wire feeder options.